Corrosion and degradation of test materials in the IGT HYGAS coal-gasification pilot plant
Corrosion monitoring of test materials was conducted in the operating environment of the IGT HYGAS pilot plant between 1974 and 1980. Metals were exposed in the coal pretreater, pretreater quench system, coal slurry mix tank, multistage gasifier, gasifier quench system, and spent char mix tank. Austenitic alloy Types 304 and 316 were found to be superior in corrosion performance compared to Type 410 and carbon steel in the coal pretreater environment. Pack aluminized coatings on carbon steel A-515 prevented attack of the substrate; hairline cracks were always observed in the coating but never penetrating the diffusion zone. Throughout the HYGAS quench systems (gasifier and coal pretreater), the 300 series austenitic stainless steels showed consistently better corrosion resistance than other test materials in all test locations. This was also true in the slurry and char mix tanks. Equivalent linear corrosion rates were less than 1 mpy (0.03 mm/y); mild pitting was encountered in some cases. Of the alloys tested in the lower gasifier stages, alloys IN-671, IN-800, and Types 310, 309, and 446 were consistently better performers. Pack aluminized alloys (Type 310, IN-800) showed no improved corrosion resistance. All refractories were exposed as 9 in. (228.6 mm) straight bricks and used as headers to brick up a manway with only their ends exposed to the gasifier environment. Dense refractories were little affected by exposure, but lightweight refractories deteriorated. In general, the physical properties and abrasion resistance of the high-alumina (90% or greater) dense refractories were degraded by exposure while those of medium-alumina (50 to 60%) dense refractories were enhanced. Any of the dense refractories would have been suitable for lining the gasifier, but a medium-alumina castable would have been the optimum selection because of its lower cost.
- Research Organization:
- IIT Research Inst., Chicago, IL (USA)
- DOE Contract Number:
- W-7405-ENG-26
- OSTI ID:
- 6754413
- Report Number(s):
- IITRI-M-06087-C; ON: DE83001287
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
010404* -- Coal
Lignite
& Peat-- Gasification
36 MATERIALS SCIENCE
360105 -- Metals & Alloys-- Corrosion & Erosion
ALLOYS
CARBON STEELS
CHEMICAL REACTIONS
CHROMIUM ALLOYS
CHROMIUM STEELS
CHROMIUM-NICKEL STEELS
COAL GASIFICATION
COPPER ALLOYS
CORROSION
CORROSION RESISTANCE
CORROSION RESISTANT ALLOYS
CORROSIVE EFFECTS
DATA
EXPERIMENTAL DATA
FUNCTIONAL MODELS
GASIFICATION
HEAT RESISTANT MATERIALS
HEAT RESISTING ALLOYS
HYGAS PROCESS
INCOLOY 800
INCOLOY ALLOYS
INCONEL 600
INCONEL 671
INCONEL ALLOYS
INFORMATION
IRON ALLOYS
IRON BASE ALLOYS
MANGANESE ALLOYS
MATERIALS
MATERIALS TESTING
METALLOGRAPHY
MOLYBDENUM ALLOYS
MONEL 400
NICKEL ALLOYS
NICKEL BASE ALLOYS
NIOBIUM ALLOYS
NUMERICAL DATA
PILOT PLANTS
SNG PROCESSES
STAINLESS STEEL-304
STAINLESS STEEL-309
STAINLESS STEEL-310
STAINLESS STEEL-316
STAINLESS STEEL-410
STAINLESS STEEL-446
STAINLESS STEELS
STEELS
TESTING
THERMOCHEMICAL PROCESSES